Vibration testing is important for machine health monitoring and predictive maintenance. A vibration meter provides a simple way to screen machine health by measuring overall vibration (OV) and crest factor plus (CF+), which detects bearing damage. The meter compares readings to baseline values for 37 machine types. Users take measurements close to bearings and interpret severity levels on a four-level scale. Data can be stored in an Excel template to monitor machine condition over time. While a vibration meter provides basic screening, a tester is needed to diagnose faults and an analyzer for complex machines.
2. Agenda
• Why vibration testing is important?
• What is the difference between vibration tools?
• Who can best use vibration tools?
• When to use vibration tools?
• How vibration testing is performed?
– Basics of vibration
– Simple steps to use vibration tools
– Steps for a successful vibration testing program
3. Why is vibration testing important?
Predictability. Studies have shown that vibration testing can provide early warnings of
impending machine failure, giving maintenance staff time to schedule required repairs and
acquire needed parts. One customer saved thousands of dollars a year by eliminating
unneeded PMs on just 1 machine all with no failures in over 3 years.
Safety. Having information about machine health enables operators to take faulty equipment
offline before a hazardous condition occurs.
Revenue. Well-maintained machines have fewer unexpected and serious failures, helping to
prevent production stoppages that cut into the bottom line. One customer increased annual
production by 4 days adding millions to the company’s bottom line
Increased maintenance intervals. When machine health is being tracked, maintenance can
be scheduled by need, not just by accumulated hours of operation. One customer increased
intervals by almost 3 years on hundreds of pumps
Reliability. Monitored machinery has fewer unexpected or catastrophic failures. One
customer reduced almost daily outages to near zero
Cost savings. Running machinery until failure often results in more expensive repairs,
overtime, excessive energy waste, and forced purchases. One customer dropped the annual
maintenance budget on a large group of critical pumps in half – hundreds of thousands $
Peace of mind. A better understanding of machine health builds confidence in maintenance
schedules, budgeting, and productivity estimates.
4. What is the difference between
vibration tools?
Here’s what happens if we take the machines in a typical plant and put them into a pyramid:
Top level - a few complex machines have many variables and require a vibration expert with an
analyzer to compare, trend, analyze and diagnose, the machine. See the complex waterfall
and analysis on the right. Refer these few machines to a consultant or in-house expert.
Middle level - most of the remaining machines
(more than 90 %) are mainstream
machines—motors, pumps, fans, compressors
and blowers that can effectively be diagnosed
using automated diagnostic programs by a
technician using the vibration tester.
Bottom level - small and
expendable machines that
would typically be ignored
can now be screened by
an operator or entry-level
technician using built-in
machine health severity
scales to indicate when
it’s time to call in more
advanced tools.
5. Who can best use vibration tools?
• Entry-level technicians use the screening tool to screen for potential problems
• Experienced technicians use the tester to diagnose common faults and root cause
• Finally, call in a service provider if needed for the few machines at the top of the
pyramid or machines with complex faults.
Benefits of Tiered
Maintenance
• Don’t spend time analyzing
healthy machines
• Reduce the number of work
orders
• Don’t deploy your experts
on simple faults
6. When to use vibration tools?
Input
Power
Quality
Drive & Drive
Output Signals
Motor
load /
windings
Motor
testing /
insulation
Mechanical
vibration &
alignment
Calibrate process
controls &
variables
Think about your assets
holistically: electricity in and
work out
- Every link in the chain is a
potential failure and some
links lie outside the physical
“machine”
Electrical (scopes, DMM)
Thermal (imagers)
Mechanical (vibration)
Oil Analysis
Ultrasonic
Vibration
Electrical
Thermography
Audible Noise
Hot to Touch
Energy Waste
Cost to Repair
• Different assets require a
different mix of technologies:
Electrical, Thermal, Mechanical
• For rotating machines,
vibration is the best tool –
ultrasound is too early and
thermography is too late
7. When to use vibration tools?
First, screen machines
to find out which ones
are good or bad
Second, diagnose machine
faults and determine repair
recommendation
Third, correct
the problem
Last step is to check
machine to ensure repair is
good and return to service
Vibration meter Vibration meter or tester
8. How is vibration testing performed?
Vibration analysis basics
Vibration for a moving object can best be illustrated as a sine wave that
repeats over and over along the horizontal axis. See below the mass on a
spring that generates a sine wave of vibration as it moves up and down over
time. One complete sine wave is a cycle. The time it takes for the cycle to
repeat is the frequency or speed of the waveform.
The vibration waveform also has an amplitude or magnitude that can be
measured in the vertical axis. There are three ways that the waveform’s
amplitude can be reported:
9. Vibration basics on machines
Vibration testing on rotating machines provides vital machine condition
information. Here are some vibration basics:
If a motor shaft turns the pump shaft at 1776 RPM for example, a heavy spot on the
shaft causes an outward force in all radial directions as the shaft turns.
This is like a hula hoop. Note: Even a healthy machine will have some vibration as the
shaft turns, but this is considered normal.
1776 Revolutions Per Minute (RPM) = 1776 Cycles Per Minute (CPM)
(Rotating shaft) (Sine wave)
10. Vibration basics on machines
The rotating motor shaft turns the pump shaft through the coupling.
• Every time an impeller vane passes the sensor, it creates a small vibration.
• If the pump has 10 impeller vanes, the sensor sees vibration from a vane 10 times
for every shaft revolution.
• The larger mass of the shaft will cause more vibration amplitude than the impeller.
• The sine wave for the pump impeller vibration will be smaller in amplitude than the
shaft vibration, but more cycles (10) for one complete shaft rotation.
10 vibrations per shaft revolution = 10 cycles per shaft revolution
(Rotating impeller vanes) (Sine wave)
11. Complex waveforms
If we superimpose the two sine waves (shaft
and pump impeller) it might look like this:
But really the vibrations add to each other
and look more like this
And 20 or 30 vibrations from different
components of a real rotating machine might
look like this
- 1 revolution of shaft
- 10 impeller vibrations per 1
shaft rotation
12. Frequency (spectrum) analysis
• The time waveform contains information about the machine, but patterns of
different components are overlapped and jumbled together
• A mathematical algorithm (FFT) converts the complex time waveform into a simple
graph called the frequency spectrum.
• It separates the individual waveforms so that we can analyze them separately. This
conversion is performed inside the tester.
• From our earlier example, we can see how the complex waveform (above on left)
is made up of two separate waveforms (above center) that can then be converted
to a spectrum (above on right) which is a simple plot of the signal’s amplitude (y–
axis) against frequency (x-axis).
Notice the amplitude of the shaft sine wave (1 cycle) is three units and
the amplitude of the pump impeller sine wave (10 cycles) is one unit.
13. Frequency (spectrum) analysis
The same thing is seen in the spectra from a real rotating machine:
– These peaks are at specific frequencies that represent vibrations going on in
the machine.
– Machine diagnostics involves matching the peaks in the spectrum with events
that exist in the machine
– Spectral analysis is the primary tool we use to diagnose the condition of
rotating machines
14. Overall Vibration (OV) analysis
Overall vibration analysis is much simpler, but there is no detail:
• From the same vibration data, one single overall vibration value is calculated,
which represents the average energy of the vibration sample.
• The meter uses this single value as an indicator of the overall health of the
machine (trend graph) and compares it to standards (ISO 10816-1)
• The tester uses this single value to help confirm the diagnostic report to and to
indicate if a problem other than a fault (foundation, resonance) may be present.
Meter Tester
15. Machine basics for rotating machines
Over 30 years, a team of vibration experts learned that machines really
aren’t that different from each other
• From a vibration stand-point, most machines are just a couple of shafts with two
bearings each and something in-between connecting the two shafts (a coupling, a
belt, or a gearbox).
• The determining factors for a machine that can be diagnosed with an automated
vibration tester isn’t size, criticality, or complexity, but rather, whether there are any
large and rapidly changing variations in machine conditions: speed, load, etc.
• Most rotating machines are pretty consistent for the time it takes to perform a
vibration test and only a few machines require an expert using an advanced
vibration analyzer. Refer these machines to a consultant or service provider.
16. Machine basics for rotating machines
For vibration testing, we can simplify a machine to one or two shafts with two
bearings each and something connecting the shafts. Look at your machine
and identify the shaft(s), bearings, coupling, and driven component.
When the motor turns does anything else turn? Is there anything on motor shaft? If yes, then
do not select #1. This option is only for stand-alone motors, such as a motor that has been
removed, repaired, and sitting on the shop floor or test bench. If anything else is connected
to the motor, the diagnosis will be wrong.
1. Motor Detached (no driven)
17. Machine basics for rotating machines
Does the machine have just two bearings? If no, then do not select #2. See #3.
This option is for situations where the pump, compressor, or fan is mounted directly on
the motor shaft.
2. Motor Close Coupled with Overhung Driven
3. Motor Coupled with Overhung Driven
This option is for machines with four bearings and two shafts going the same speed.
Most machines have some type of flexible element between shafts to allow give.
18. Machine basics for rotating machines
This option is not very common. It is for machines with four bearings and two shafts going the
same speed, but with a solid shaft (no flexible coupling). Most machines are either close
coupled (#2) or have a flexible coupling (#3).
4. Motor No Coupling and Supported Driven
This option is for machines with four bearings and two shafts going different speeds. It is very
important to identify the speed of both shafts. If possible, finding the belt speed will help
eliminate false bearing calls.
5. Motor with belt-drive and overhung driven
19. Machine basics for rotating machines
This option is for machines with four or more bearings and two shafts going different speeds. It
is very important to identify the speed of both shafts. If possible, finding the gear teeth count
will help eliminate false bearing calls.
6. Motor, Coupling, Gearbox, Coupling, Driven
This option is not very common. It is for machines with four or more bearings and two
reductions (gearbox and belt). It is very important to identify the speed of both shafts and both
reductions. Multiple intermediate components like this are very rare.
7. Motor, Coupling, Gearbox, Belt-drive, Driven
20. Machine basics for rotating machines
What is on the inside? Pumps
Centrifugal Propeller Piston
Lobed Sliding vane Screw
21. Simple steps to use vibration tools
First step - setup the tool
to test the machine
Step two - take measurements
from the machine
Step three - diagnose faults
and decide if action is needed
AnalyzerTesterMeter
Only need to
know machine
name and type
Fast, 1 second test
in 1 direction only
on 1 or 2 bearings
of machine
Screen health of
machine in seconds
=> good or need
further testing by tester
Quick setup using
machine setup
wizard – basic
information that
technician knows
3 (simultaneous)
axis of high-
resolution data
takes < 1 minute on
3 or 4 bearings of
the machine
Diagnoses most
common machine
faults automatically in
< 5 minutes and
provides severity with
repair recommendation
Analyst needed with
deep understanding
of vibration to select
optimal frequency
ranges and setup
complex program
Detailed analysis by
an expert for complex
faults or complex
machines – in 30-40
minutes
3 (1 at a time) axis
of high-resolution
data takes 1-2
minutes on each of
3-4+ bearings of the
machine
23. Vibration meter – overall vibration
• Mechanical vibration is a notoriously difficult subject matter to master
• The vibration meter yields significant benefits without requiring advanced training
by end-users
• All vibration data is collected in the time domain from a piezoelectric
accelerometer.
• The time domain data is used to calculate one single overall vibration value that
can be used as an indicator of the overall health of the machine and can be
trended over time. This number is like an average of all of the energy.
0.20 in/sec
Overall
Time domain data Overall Vibration (OV) Trend plot
24. Vibration meter – Overall Vibration (OV)
Three limitations of overall vibration and the solutions:
1. Different machine types have different healthy levels of overall vibration
Solution – use a database of different OV levels for 37 machine categories
2. Bearing flaws will not cause an alarm in OV until significant damage occurs.
Solution – use high frequency Crest Factor + to detect the impacting of bearings
3. A severe level of OV does not identify the root cause fault of the machine
Solution – trend the OV and use a vibration tester to diagnose the fault
25. Crest Factor +
• A limitation of overall vibration analysis is bearing flaws will not cause an
alarm until significant damage has occurred
• Crest Factor looks in the high frequency for bearing impacting
• Crest Factor Plus is a proprietary weighted calculation that is a significant
step forward from traditional crest factor vibration analysis because the
output value (CF+) increases continually as the bearing damage worsens
Vibration meter – Crest Factor (CF+)
0
2
4
6
8
10
12
14
Jan Feb Mar Apr May Jun Jul Aug Sep Oct
CF
CF +
26. 26
Vibration meter – overview
Rugged - made of tough, heavy plastic.
Feels solid and well-balanced in your hand.
Green light indicating right amount of pressure
is applied (wait 3 seconds after pressing
Measure button taking a measurement)
Three measurements: overall vibration, bearing
condition and temperature reliably
Two severity levels: Four-level severity scale both
overall vibration and bearing condition using textual
alerts (Good, Satisfactory, Unsatisfactory,
Unacceptable)
A combination force sensor tip and vibration sensor
compensates for user variance (force or angle) yielding in
accurate, repeatable readings.
Tip is specially designed to get both low frequency (OV) and high frequency (CF+)
measurements.
27. How to Setup your machine – just once
STEP 1 – SETUP : Press the grey “Setup” button
1. Use the arrows to select “Create NEW setup”, Press “Enter”.
2. Use arrows to scroll through 37 predefined machine categories.
Select “Horiz Centrif – Single Suction” pump (for both pump & motor)
3. Motor 1800 RPM => Select RPM Range > 600 RPM, press “Enter”.
4. Enter machine name - use arrows to move from one character to next.
Push “Enter” button to confirm. To delete characters, push “Back”.
When name complete (TW Pump 3), Press “Save”
1 2 3 4
29. Vibration meter – where to measure
Locate the sensor tip as close as possible to the bearing, or on a solid structural
member leading to the bearing
30. How to Screen Machine Condition
INTERPRETATION OF MEAUREMENT
Severity scale gives a better understanding
of the overall vibration and bearings.
CF+ Scale (Bearing health):
0 - 5 = Good
6 -10 = Satisfactory
11-15 = Unsatisfactory
16 & > =Unacceptable
Overall Scale (Machine health):
Depends on machine type
(which of the 37 machine categories
did you select?)
31. Store Data to Excel template
X-Axis on bottom = time
Y-Axis on left = OV-Velocity (Light blue plot trending up)
Sec-Y on right = CF+ (Dark blue plot at zero)
32. Vibration meter - ISO Standard
10816-1: General guidelines machine vibration measurements on
non-rotating parts
1. Class 1 – Engines and integrated machines
2. Class 2 – Medium-sized machines (15 -75 kW output)
3. Class 3 – Large machines on rigid, heavy foundations
4. Class 4 – Large machines on soft foundations
10816-3: Industrial machines with nominal power above 15 kW
and nominal speeds between 120 RPM and 15,000 RPM when
measured in situ
1. Group 1 – Large machines > 300 KW and < 50 MW
2. Group 2 – Medium-sized machines > 15 kW and <=
300 kW
10816-7: Rotor dynamic pumps by measurements on nonrotating
parts
1. Category I – Pumps with a high level of reliability and
safety
2. Category II – Pumps for general or less critical
applications
Excel template Overall Vibration Severity refers to one of three ISO Standards:
34. External Sensor – how to use
1. Find a short & solid transmission path
from the rotating shaft to a bearing and
wipe the metal surface with a rag to
remove dirt and grease.
2. Locate the sensor securely on a solid,
bare, metal surface of the bearing housing
(not on a thin cover).
3. Roll the sensor when using a magnet
mount to prevent damage to the crystal
and check magnet has a good grip.
4. Ensure the measurement is taken under
normal operating conditions.
36. Vibration tester - overview
Three easy steps
to get machine
condition answers
37. Vibration tester - Setup machine
How to answer the setup questions for a vibration test
To accurately diagnose a wide range of machine conditions, the 810 needs a
complete and accurate description of the components being tested and how they are
configured. This machine setup information tells the 810 software where normal
vibration peaks should be expected.
To gather the required information quickly and
conveniently, the Tester asks a series of
questions about the following topics when you
set up a new test:
• Motor that drives the system
• Couplings and transmission
• Driven component
As you answer these questions, the Fluke 810
Vibration Tester displays an image of the
system that you have described so you can
be sure that it is accurately represented.
HINTS AND TIPS
Some complex machines can be treated as if they are
just two or more standard machines combined.
38. Different ways to find speed for a shaft
1. Laser tachometer
• Need to stop machine and attach reflective tape
• Very accurate and easy to use (Spikes Per Minute = RPM)
• See operation during the 810 Measure video (later)
• Preferred method but not always convenient
2. Contact tachometer
• No need to stop machine to attach reflective tape
• Not always the best method – limited access & safety concerns
• Need to have physical contact with rotating component
• No limit of shaft speed or lighting conditions (like stroboscope)
3. Stroboscope
• No need to stop machine to attach reflective tape
• Best method unless shaft speed is very low (< 500 RPM)
• See operation on next slide
• FPM (Flash Per Minute) = RPM
4. Display on the variable frequency drive (just do some quick math – it doesn’t have
to be exact, just in the ball park) VFD % X motor nameplate speed
5. Use the 810 to find the speed (just setup a test for a small stand-alone motor)
Take one measurement from the motor bearing, Diagnose, and find 1X peak (biggest
peak). The speed of the peak will be shown in Cycles Per Minute (RPM).
39. Why a stroboscope is needed
• Quickly “freeze” fast-moving machines or processes to observe or identify without
having to shut-down the operation — Is the speed correct? Is something wrong?
• LED Stroboscopes are rugged and easy to use tools to troubleshoot and inspect
machines without contact and without stopping production (take in your tool bag).
• Read RPM on display and manually enter speed into the Vibration Tester
Common uses for the stroboscope:
• Turbines vary in speed and change speed frequently
• VFD motors vary in speed, but do not change frequently
• Visually inspect fast moving parts for problems without shutdown
• Find belt rotation speed and look for belt slippage (compare pulley speeds)
• Find machine element components and part numbers – fan blades, pump
vanes, compressor screws, gear teeth, etc. without shutting down
• Inspect leading edge damage and material buildup on fan blades
• Investigate repetitive moving processes for flaws, timing problems, or
misfires
Hundreds of industrial uses and applications:
• Electronics/electrical engineering
• Shipbuilding, aircraft construction
• Food & beverage, manufacturing
• Print, paper, cardboard manufacturing
• Optics manufacturing
• Machine construction
40. Vibration tester: Setup machine –
follow steps of wizard
What if you don’t know the answer to a Setup question?
Many answers can be assumed. Some answers can be left blank.
Some answers are critical to achieve an accurate diagnosis.
If in doubt: Some entries can be assumed without sacrificing accuracy.
Example: If in doubt, select roller bearings.
Optional: Some entries can be left blank at the beginning, but should be
updated later when the information is found. Some missing information
can lead to misdiagnosis.
Important: All other items are critical and need to be filled in or the
accuracy of the diagnosis may be in question.
Journal bearings include any
bearing without rolling elements:
sleeve, journal, Babbitt, etc. and
use soft metal and sometimes an
oil bath instead of rolling
elements.
Roller bearings include any bearing
with rolling elements: balls, cones,
tapered roller, etc. and have a different
wear pattern than journal bearings.
CAUTION
41. Vibration tester - Measure machine
1. Vibration transmits down the
shaft, through the bearing, into
the bearing housing, into the
sensor magnet and into the
sensor.
2. The triaxial sensor measures
vibrations in all three directions
simultaneously.
3. The sensor converts vibrations
to an electrical signal and
transmits it to the tester
Where to mount the sensor? For vibration testing, we can simplify things to a simple shaft with
two bearings. Look at your machine and identify the shaft, bearings, coupling, and driven element.
Then mount the triaxial sensor on the bearing housing or as close to the bearing as possible
42. Measure machine – sensor mounting
Where to mount the sensor?
It is really quite simple: mount the sensor
on solid metal anywhere on or near the
bearings but not on thin covers
43. Measure machine – mounting examples
Motor close coupled (single shaft) machines
Don’t measure from pump housing or middle of motor. Measure from bearing housing.
Vibration from impeller will transmit to bearing #2. Vibration from bearing #1 will transmit
to bearing #2. If motor is small (40HP or less), collect data from motor bearing #2.
If large, collect data from both bearings Not a bearing or a coupling.
Seals keep water in the pump
from entering the motor.
Do NOT measure from here.
On motors without a cooling fan, it is
OK to mount the sensor on the end of
the motor as long as the metal is solid.
No bearings on pump.
Do Not measure from
pump. You will only see
flow noise. Only
measure from bearings.
44. Easy measurement – follow screen icons
1
2
3Press Diagnose then review4
Select location on machine – sensor location number
Select orientation on the machine – sensor located on bearing in relation to shaft
Select orientation of sensor – is the sensor cable perpendicular or aligned with the shaft
45. Vibration analyzer – manual analysis
Vibration analysis can be simplified to a three-step process:
1. Identify vibration peaks as they relate to a
source component on the machine.
2. Look for patterns in the data based on
vibration rules.
3. Measure the amplitude of the vibration peak
to determine the severity of the fault
Once the fault and severity are determined, a repair can be recommended and a
work order generated. There are hundreds of faults, but most are infrequent or
rarely seen. Instead of learning hundreds of rare faults, learn the four most common
machine faults that you will find every day and are easy to correct:
1. Imbalance
2. Misalignment
3. Looseness
4. Bearing Failures
46. Vibration tester – automated analysis
Automated machine diagnostics of the vibration tester
Turns vibration data into machine condition answers:
Quick, easy, and proven accurate:
1. Easy setup – Machine wizard uses default settings to help the user
2. Complete measurement – Icon-driven menus and triaxial sensor
3. Reliable diagnosis – Proven program modeled after expert analysis
4. Review final results – Review the data and setup on the Viewer software
5. Make repairs – Measure again to check work and verify the before/after condition
Feel confident about the severity of your machine faults and repair recommendations
by reviewing and validating the vibration data yourself.
47. Vibration tester - review the report
Review the machine condition report and then decide what action is needed:.
Name of machine tested
Bearing locations measured (notice only 3 of the 4
locations were tested)
Reference data to verify valid measurement and
identify other possible concerns
Faults, Severity, Severity Score (1-100) ,
Severity Scale (green-yellow-orange-red)
Recommendations, Priority, Priority Description
48. • Start small and grow show success get more budget to grow. The #1
killer of a new program is starting too big. You are still setting up hundreds of
machines, but results are expected now, so someone at the top will pull the plug on
the resources. A smarter method is to start with 25-50 assets (under the radar of top
management) and get a few successes. Then wave the flag to let everyone know
that reliability is paying off in a big way. This is a better recipe for success than
trying to change company culture overnight.
• Start with simple machines at the beginning and focus on problem machines.
Add tough machines as your training and experience grows.
Start-up a successful vibration program:
Program Pillar #1 – new program start-up
Example Criticality List (Excel) Example Asset Test Schedule (Excel)
49. • Use automation and proven measurement methodology to get a complete
picture of the machine’s entire power train.
• The #1 killer is choose one maintenance technology and just measure
everything you can. Maintenance technicians and operators don’t have time to look
over reams of data—they have a plant to run. The goal should be a system that
screens the data and provides answers about what is wrong with a machine and
what to do to fix it.
• A better method is to focus on the likely failure modes, and match the right
maintenance technologies to the most likely failure mode.
Start-up a successful vibration program:
Program Pillar #2 – Technology selection
50. Pillar 3 – Database management
• #1 killer of an existing program is data overload – what to do with all of the
new data? Unless data is converted to machine condition answers then the
program is doomed to fail. The real power of Tiered Maintenance is unlocked
when the advanced tools from multiple technologies have the ability to transfer
measurements to a single database that allows everyone on the team to
collaborate in real time and flag or escalate issues up the tiers.
• Team members need access to full measurements history on a given machine
from anywhere in the field or on the plant floor or from home.
51. Why a vibration meter is needed
• Screening and repairing machines only when they fail
decreases production revenue while increasing energy waste
and maintenance costs
• Seeing early warnings of impending machine failure
empowers maintenance staff time to schedule repairs
Just like a nurse that takes your vital signs before you see the doctor, the
vibration meter screens your machine with 3 simple tests to check its health
It has a built-in database of overall vibration levels from years of analyzing
thousands of real machine
External Sensor - allows technicians to get into tight places to take vibration
measurements where the stinger probe doesn’t otherwise fit.
Answers not just data – Five tools in one:
1. Bearing health— 4 level severity score: good or bad
2. Bearing impact— high frequency vibration plus trending
3. Overall machine health— 4 level severity score: good or
bad compared to real data from 37 machine categories
4. Overall vibration— low frequency vibration plus trending
5. Temperature— Infrared temperature of bearing surface
Built with
FLUKE CONNECT
52. Why a vibration tester is needed
A simple three step process provides machine condition answers
without difficult analysis.
• Repairing machines only when they fail decreases production
revenue while increasing energy waste and maintenance costs.
• Seeing early warnings of impending machine failure empowers
maintenance staff time to schedule repairs.
• Most machine failures come from four common faults: imbalance,
misalignment, bearings and looseness.
Just like a doctor that diagnoses most problems without the need to see a
specialist—90 % of machines are standard motors, pumps, fans,
compressors, blowers, gears, belts that have very few variables.
Reduce training costs:
• Easier and faster measurement using the triaxial sensor
• Automated built-in expert diagnostic engine
• Extensive setup, trending, analysis, on-site expert not needed to get machine answers
• Training is the key to a successful proactive maintenance program — easy to learn the steps
to review diagnostic results
The vibration tester has a proven auto diagnostic program based on 30 years
of machine baselines to analyze machines for you and get you back to work.
53. Click to edit Master title style
Questions or Comments?
Email Nicole VanWert-Quinzi
nicole.vanwert@Transcat.com
Transcat: 800-800-5001
www.Transcat.com
For related product information, go to:
www.Transcat.com/Megger
Hinweis der Redaktion
Welcome the audience and note the title of the course, “Fluke 810 Vibration Tester Training Program.”
Introduce yourself, telling a little about your experience and what you have to offer.
Before presenting, make edits to the slide (if desired) – add your name, company being trained, plant location, etc.
In order to keep the plant up and running, we need to look at the various tools that make up the maintenance chain.
See how multiple tools equal more than the sum of their parts.
In practice, some terms can mean different things to different people. To keep things simple in the training manual:
Pumps move liquids, fans move air, blowers move a lot of air, compressors compress air or gas
If the machine is not a pump, fan, blower, or compressor, then select spindle (or simple shaft)
Examples: Multi-stage vanes or heavy lobes are blowers; axial blades or squirrel cage are fans;
A mixer could be a pump (moves liquid) or a spindle (simple shaft with something on the end)
In this section, we will cover how to Setup and Measure your machines.
When a bearing is first starting to fail due to a flaw on the outer race, inner race, or ball/roller, very short duration spikes will appear in the time domain each time the flaw makes contact with an adjacent bearing component.
These spikes have very low energy, and therefore cause very little change to the overall vibration value. Crest Factor is a technique we can use to see these low energy bearing impacts in the high frequency.
As the bearing damage progresses, the spikes will continue to increase in energy along with the baseline vibration of the machine, and ultimately will cause the RMS value to increase which causes the CF value to decrease. (see the blue trend plot labeled CF)
“Crest Factor Plus” adds the RMS value back into the equation which gives a more better trend of the bearing wear (see the red trend plot labeled CF+)
CF+ identifies bearing flaws much earlier than a simple overall vibration meter is capable of and shows the bearing severity increasing as the bearing nears the end of life.
Read slide
Read slide
For the Overall Vibration severity scale, you must Setup the Meter to recognize the type of machine, or Machine Category, for the test. A list of the most common categories is programmed into the Meter. When the Meter is set to a category, it can compare for the typical vibration levels of different machine types. The database inside the 805 has overall vibration levels typically found in industrial machines selected by one of 37 machine categories.
After these parameters are set, the Meter shows the overall vibration and bearing measurements with a severity scale for each measurement. The overall vibration severity scales use a statistical analysis of data from thousands of industrial machines. Keep in mind when you use the severity scales:
• The severity scales are only applicable to machines at speeds from 600 RPM to 10,000 RPM.
Make measurements with the accelerometer as close as possible to the bearing housing.
• The severity scales are not applicable if the machine is installed on spring or pad isolators.
• Severity scales for motors match the machine that they operate. For example, when you do a test on a motor that operates a centrifugal pump, select the applicable centrifugal pump Machine Category for all test points on the motor and pump.
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The Severity Scale gives the user more than just a number with no meaning. It provides a better understanding of what action should be taken.
There are two Severity Scales:
One is based on Crest Factor + and shows the bearing health – this scale does not depend on machine type and does not require a machine category during Setup.
The other is based on overall vibration and shows the machine’s health (shaft vibration). This scale depends on comparison of similar machines and does require one of the 37 machine categories to be selected during Setup. If machine category is not selected, this Severity Scale will not be displayed.
If your machine is not on the list, then the database does not have overall values stored for comparison. Examples of machines not listed are engines, turbines, generators, etc. These machines have high variations in overall values. Even though you won’t see a Severity Scale for overall vibration, you will see a Severity Score for CF+ along with the 3 readings – overall vibration, CF+ and temperature. Simply trend these readings and trend over time to find your own alarm levels.
You can export your measurements to MS Excel on your PC to trend overall vibration, CF+, and IR temperature.
Use a mini USB to USB cable to connect the meter to your PC.
Although ISO 10816 doesn’t need a machine category to compare OV levels, it is not as specific.
The standard compares the OV level to only 2 or 4 machine types instead of 37 machine types.
The most common (-1) compares the OV to 4 machine sizes. There is no consideration for machine type only the size of the machine. You can see that this is not very specific to your type of machine and it is very general.
In addition to the trending available using the Excel template, you can also use the trending and features found in Fluke Connect.
Fluke Connect allows you to share data among many different Fluke tools and share answers with everyone on your team.
This sharing breaks down the traditional information silos that have plagued maintenance teams for years.
Follow these 4 simple steps to use your 805 with Fluke Connect.
Use the 805FC without the external for most measurements, but use the external sensor for hard to reach places.
Do not mix data from different sensor types into a single trend. Different mounting methods have a different frequency response.
In this section, we will cover how to Setup and Measure your machines.
On this page we see the main parts of the 810 Vibration Tester including the connections and the main screens
The 4 connections on the top are:
The included triaxial sensor for taking 3 simultaneous measurements
The laser tachometer for taking the speed of the rotating shaft
The mini USB cable to connect to the Viewer software on your PC
And the connection for an optional single channel vibration sensor
The main screens are:
Instrument Setup and Info screens are used infrequently to Setup the instrument
The three easy steps have their own button on the 810:
Setup your machine using step by step wizard
Follow screens to take quick Measurements with triaxial sensor
With a press of the button, the automated Diagnostic program analyzes the data, identifies the fault, and provides a report with the repair recommendation.
All you do is review the results to validate the data and determine if there is any action now or wait until later.
The vibration tester was not designed to replace the vibration analyzer or an expert, but to compliment the in-house program or consultant. The vibration tester was designed to quickly find and diagnose the most common problems on a vast majority of machines. The tester cannot diagnose complex machines with exotic variables. For these machines, plants still need the vibration expert or vibration service to compare, analyze and build baselines.
Fluke Connect provides collaboration across all tiers:
First on the left, you can see All Asset Categories, this is what a typical plant looks like. There are a lot of different Asset Types that the maintenance team is tasked with maintaining
Along the bottom are the wide assortment of Measurements Technologies needed to maintain all of the Asset Types. You can see all of the measurement technologies connect with Fluke Connect.
And really the most important part of all is that All Team Members need to be able access those readings. The data silo problem is a real challenge and the most frustrating problem that is keeping data from the people that need to see it.
There are over 30 connected tools:
Capture & Save Measurements
Add Voice or Text Notes
Create Trend Lines
Share Live with Team Members
Escalate Issues to Managers
Generate Work Order Requests
Send Data to 3rd Parties
Measure From a Safe Distance
Could better tools influence better work practices and better collaboration and better maintenance culture?
